Lifetime modelling of electrical machines using the methodology of design of experiments

Hanisch, Lucas Vincent; Henke, Markus

doi:10.11128/arep.59.a59045

Cited by 2 publications

(2 citation statements)

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“…Above a critical field strength, the necessary activation energy ∆G is exceeded, the free path length of the electrons reaches a constant maximum value and the polymer chains are broken. This damage mechanism leads to electrical breakdown after a certain time [126]- [128].…”

Section: ) Physical Models For Electrical Agingmentioning

confidence: 99%

The Insulation Resilience of Inverter-Fed Low Voltage Traction Machines: Review, Challenges, and Opportunities

2022

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The use of wide bandgap (WBG) semiconductor devices, which enable higher switching slew rates, and the increase in DC link voltage, which provides system-wide advantages, exposes the winding system of traction machines to enhanced electrical stress. The resulting nonlinear voltage distribution along the motor winding favors partial discharges (PD), which in low voltage (LV) machines causes excessive damage to the insulation system, and premature failure can occur. A simple solution by increasing the enamel thickness of the wires leads on the one hand to a lower copper fill factor. On the other hand, this measure is not necessarily accompanied by an increase in electrical resilience in the case of pulsed voltage. It is therefore essential to understand the phenomenon of partial discharges, which is composed of a large number of processes and mechanisms, to be able to make an estimation of aging. The ultimate goal is to derive a lifetime model that links the dynamic load collectives -ideally in conjunction with the environmental stress influences -of a traction application to a usage-dependent and realistic prediction of the residual lifetime. To this end, this paper provides an overview of the current state of science and technology in this interdisciplinary topic by describing, with reference to high voltage (HV) technology/engineering, the design of the insulation system, the discharge physics, the degradation mechanisms, the statistical effects to be considered, and the partial discharge measurement methods.

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Section: ) Physical Models For Electrical Agingmentioning

confidence: 99%

The Insulation Resilience of Inverter-Fed Low Voltage Traction Machines: Review, Challenges, and Opportunities

2022

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“…Additionally, temperature (both ambient and operating) plays a crucial role in the aging of electrical components due to thermal stress. Related research has been carried out for traction battery durability [7,8], EM durability [9][10][11], power electronics [12], and the electric system [13]. The mechanical components in electric vehicles are subjected to more critical working conditions than those in conventional vehicles with multi-stage transmissions.…”

Section: Introductionmentioning

confidence: 99%

An Investigation of Representative Customer Load Collectives in the Development of Electric Vehicle Drivetrain Durability

Li,

Noering,

Öngün

et al. 2024

WEVJ

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To ensure the precise dimensioning and effective testing of drivetrain components, it is crucial to have a thorough understanding of customer requirements, with a particular emphasis on customer stress on these components. An accurate interpretation of customer data is essential for determining representative customer requirements, such as load collectives. The automobile industry has faced challenges in analyzing large amounts of customer driving data to obtain representative load collectives as target values in durability design. However, due to technical limitations and cost constraints, collecting data from a large sample size is not feasible. The ongoing digitalization of the automotive industry, driven by an increasing number of connected vehicles, enhances data-based and customer-oriented development. This paper investigates representative customer load collectives using cloud data from over 40,000 customer vehicles to lay the groundwork for realizing robust requirement engineering. A systematic method for analyzing big data on the cloud was introduced. The derived component-specific damage distribution from these collectives adopts a unique approach, utilizing the 1% vehicle term instead of the common 1% customer term to represent typical customer stress. This study shows that the driven mileage and the number of vehicles are crucial factors in 1% vehicle analysis. An analysis of the characteristics of the 1% vehicle is conducted, followed by an exploration to determine the required vehicle quantity for obtaining stable results. The shape parameter of the damage distribution determines the necessary number of vehicles for a reliable conclusion. Additionally, a comparative analysis of market-specific customer requirements between the US and Europe is presented, and real usage differences in customer operations are explained using an operating point frequency heatmap. The information presented in this paper provides valuable input for optimizing durability design and conducting efficient, customer-oriented tests, resulting in significant reductions in development time and costs.

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Lifetime modelling of electrical machines using the methodology of design of experiments

Cited by 2 publications

References 0 publications

The Insulation Resilience of Inverter-Fed Low Voltage Traction Machines: Review, Challenges, and Opportunities

The Insulation Resilience of Inverter-Fed Low Voltage Traction Machines: Review, Challenges, and Opportunities

An Investigation of Representative Customer Load Collectives in the Development of Electric Vehicle Drivetrain Durability

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